Client Context

A UK-based paper mill and global leader in papermaking was struggling with high levels of unplanned engineering downtime. Asset unreliability was impacting production targets, increasing waste, and placing pressure on safety, costs, and customer service levels.

The Challenge

The client needed to maximise asset utilisation, significantly reduce unplanned downtime, and improve maintenance work completion rates—all while maintaining strict safety standards and cost control.

Cornerstone’s Approach

Cornerstone conducted a detailed analysis of the entire engineering and maintenance workflow. This included auditing maintenance shutdowns, reviewing maintenance strategies, and engaging frontline teams to understand root causes of asset unreliability.

The solution focused on doing “the right maintenance jobs, at the right frequency, and doing them right the first time.”

Key actions included:

• Developing a clear maintenance strategy and standardised maintenance routines

• Implementing a structured planning system for all maintenance work on the shop floor

• Deploying Clearview® digital planning tools, KPIs, control points, and performance reports

• Establishing continuous improvement and knowledge management systems to capture learning after each maintenance shutdown

Results Achieved

• Unplanned engineering downtime reduced by almost 70% on major assets and 10–15% on smaller assets

• Maintenance work completion rates increased from 60% to 95%

• Improved machine reliability, smoother start-ups, and increased asset availability

• Reduced product waste and improved staff morale through clearer processes and accountability

Client Impact

The paper mill achieved sustained improvements in asset reliability and operational performance, directly improving customer service levels and long-term production stability.